Final Product Created

Here is my product, a portable chair, fully completed.

Final Layers Before Completion

Evidence of me attaching the final layers together (to fix the safety hazard), and to complete the construction of my product.

Method Of Attachment For Final Layer

For the final layer (to fix the safety hazard of the hex nuts), i have applied a strong, adhesive spray, as shown.

Safety Hazard

Now that the chair is attached together, I have realised that the hex nuts, could present a safetey problem as they are sticking out from the chair, and when in use, they could brush up against it and become injured. To fix this, I will permanently attach the two additional tesselated components ( consisting of 3 layers each) to the sides of the chair. The only difference that will occur, is that the holes will now have a diameter of 40mm, so the nut and washer can still be accessible, thus keeping the function of portability, intact.

Excess Material Solution

The solution I will use against this newly formed safety hazard, is that i will cut off the excess material with a hack saw.

Thread Rod Problem

Now that the final layers of my chair are complete, I now have to tighten the thread rods, with the hex nuts. However once they were fully tightened,  a problem arose, as the excess materials were cleary protruding from the sides of the chair, this became a serious safety hazard, so I must now find a solution to this problem.

Compilation of components

This is evidence of my components, compiling together, to form my chair.

Further Evidence of Production

Now that I have all my components ready, I have begun to compile my duplicated components together (as shown). The top picture is the progress I have made so far.

Evidence of Production

This is evidence of me in production. Here, i am modifying the length of the thread rods, cutting them down from the default size of 100cm, down in half to 50cm. The size of these thread rods (once cut) will be the full width of my chair.

Additional Components

These are the additional components (which i did briefly outline in a earlier post) that are now a part of my chair. The reason as to why i have added them is that these will fill the gapes that are within the main components, once they are together. as these components are now added, i will have to add another thread rod to the lower section of the spine of the chair, for further support. This now totals the thread rods to six.

Thread Rod Test

Before I continue my production of my enlarged product, I must first create a small test, in regards to the sizing of the holes, to ensure that the rods stay firmly and safely within my product. The hole diameters begin with 11.5mm, and rise to 13.5mm. With the test completed, it shows that a 12mm hole will be a sufficient size for the rods. Now I am able to begin full production with my product.

Change in Production

Due to the sizing of the machinery that is available, the first component I had previously created would be too small for a young adult to use on a daily basis (as shown in my previous post). With that in mind, I have now scaled up the size of my product, so the chair will now consist of more components, as I now have to split my product into two parts, the base and the seat (again, due to the limitations of the machinery that is available to me. I will also have to add another steel rod to my design, for further stability, totalling in five). These are some of the parts of the scaled up model, however due to the steel rods, I will have to conduct a hole test, to see what size is most secure, before I begin to cut out the parts again, and build up the layers of the chair.

1st problem solved

my solution to the durability problem I have faced is that instead of having the conventional seat, i am going to use the side component, as a template, to create many duplicates to then attach together with 4 thread rods. This will now make the seat more durable, and more stable, as the thread rods will provide support and a form of keeping the chair together, so there will be no need to insert glue to attach them all together, as the rods will compress the cards together, forming a tight hold. the rods will be secured with hex nuts and washers.

1st Problem: durability of completed component

Once my first component was finished, I decided to do a small, durability test, by applying a small amount of pressure downwards, on the component (as shown), to find out if the component is strong enough. This has lead me to the conclusion that my component is too weak to handle the weight of a human being; I must now find a way to adapt or even change the design of the chair, so it can become durable enough to be used.

Start of production

Now that my materials arrived today at midday, I have managed to start production on the 1st component, one side of the portable chair.